Thermal Dynamics Pak Master 25 User manual

Manual No. 0-2577
October 31, 2002
Air Plasma Cutting System
For 110VAC Systems
The System Includes:
• Pak Master
®25™ EMC Power Supply
• EMC PCH-25Torch with Leads
• Input Power Cable
• Work Cable with Clamp
Operating Manual
R
EUROPEAN

Read and understand this entire Manual and your employer’s
safety practices before installing, operating, or servicing the
equipment.
While the information contained in this Manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Pak Master 25 EMC Air Plasma Cutting System(110VAC)
Operating Manual No. 0-2577
Published by
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1994 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liabil-
ity to any party for any loss or damage caused by errors or
omissions in the Pak Master 25 EMC Air Plasma Cutting System
(110VAC) Operating Manual, whether such errors result from
negligence, accident, or any other cause.
Printed in the United States of America
October 31, 2002
WARNING
WARNING

Purchase Date
Power Supply
Torch
Record Serial Numbers For Warranty Purposes

TABLE OF CONTENTS
GENERALINFORMATION............................................................................................................. i
Notes,Cautions andWarnings ................................................................................. i
Important Safety Precautions .................................................................................. i
Publications .............................................................................................................ii
Note, Attention et Avertissement ............................................................................ iii
PrecautionsDe SecuriteImportantes .....................................................................iii
DocumentsDeReference ....................................................................................... v
Declarationof Conformity.......................................................................................vii
StatementofWarranty .......................................................................................... viii
SECTION1: INTRODUCTION& DESCRIPTION ......................................................................... 1
1.1 SYSTEM DESCRIPTION ................................................................................ 1
1.2SYSTEM OPTIONSANDTORCH PARTS ........................................................ 2
SECTION2: INSTALLATION ........................................................................................................3
2.1UNPACKINGAND CHOOSING ALOCATION ................................................... 3
2.2 ELECTRICALCONNECTIONS ........................................................................ 4
2.3 GASCONNECTIONS ...................................................................................... 5
SECTON 3: OPERATION ............................................................................................................. 7
3.1 OPERATINGCONTROLS................................................................................ 7
3.2 GETTING STARTED........................................................................................ 8
3.3 SEQUENCE OF OPERATION ......................................................................... 9
3.4 CUT QUALITY ................................................................................................10
3.5 OPERATINGTHE SYSTEM ...........................................................................12
3.6OPERATINGWITH AHANDTORCH................................................................14
3.7 RECOMMENDEDCUTTINGSPEEDS ...........................................................15
SECTION4: CUSTOMER/OPERATORSERVICE .......................................................................17
4.1 POWER SUPPLY SPECIFICATIONS .............................................................17
4.2 TORCH SPECIFICATIONS .............................................................................18
4.3 REPLACEMENTTORCHESANDLEADS ......................................................19
4.4BASICTROUBLESHOOTING GIUIDE ANDMAINTENANCE ..........................20
4.5 REPLACINGCONSUMABLETORCH PARTS.................................................22
4.6 GENERALTORCHMAINTENANCE ...............................................................23
4.7 SERVICINGTORCH HEADCOMPONENTS...................................................24
4.8 REPLACINGTORCHAND LEADS .................................................................28
SECTION 5: PARTS LISTS.........................................................................................................31
5.1 REPLACEMENT COMPLETE ASSEMBLIES.................................................31
5.2 REPLACEMENTHANDTORCHPARTS .........................................................32
5.3 MISCELLANOUS PARTS ...............................................................................33
APPENDIX I: SYSTEM SCHEMATIC .........................................................................................34

TABLE OF CONTENTS (continued)

Date: November15, 2001 (Special) i GENERALINFORMATION
GENERAL INFORMATION
Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sionalandthemanufacturerofthehealthequipment
to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structionsbeforeusing the equipment. Call1-603-
298-5711 or your local distributor if you have any
questions.
GASESAND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Always readthe MaterialSafety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
Publications, in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com-
bustibleor explosive gases or materials arelocated.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de-
fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”

GENERALINFORMATION ii Date: November 15, 2001(Special)
•Wear dry glovesandclothing. Insulate yourselffrom
the work piece or other parts of the welding cir-
cuit.
• Repair or replace all worn or damaged parts.
•Extracaremust be taken whentheworkplaceismoist
ordamp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection Publications.
•Disconnect powersourcebeforeperforming any ser-
vice or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
•Do not cut or weld on containersthat mayhave held
combustibles.
• Provideafirewatch when working in an areawhere
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noisecan causepermanent hearingloss. Plasma arcpro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the deci-
bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection, Publications, in this manual.
PLASMAARC RAYS
PlasmaArc Rays caninjure your eyesandburn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesand burn yourskin if youarenotproperlyprotected.
• To protect your eyes, always wear a welding hel-
metor shield. Alsoalways wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Thesevalues applywherethe actualarcisclearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work-
piece.
Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, Wash-
ington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELD-
INGAND GAS WELDING AND CUTTING, obtain-
able from the Superintendent of Documents, U.S.
GovernmentPrinting Office,Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATIONAND EDUCATIONAL EYEAND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broad-
way, New York, NY 10018

Date: November15, 2001 (Special) iii GENERALINFORMATION
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards In-
stitute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPAStandard70, NATIONALELECTRICALCODE,
obtainable from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900Arch Street, Philadelphia, PA19103
14. American Welding Society StandardAWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPA-
RATION FOR WELDING AND CUTTING OF CON-
TAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupantà l’arc au jetde plasma produitde l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au person-
nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
lesavertissements,toutes les précautionsde sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.

GENERALINFORMATION iv Date: November 15, 2001(Special)
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtementsse trouvant sur lemétalet desdifférents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page v.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenantdessolvants etdes produitsde nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ceproduit,dans leprocéderde soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir
des éléments reconnu dans L’ état de la Californie,
qui peuvent causer des défauts de naissance et le
cancer. (La sécurité de santé en Californie et la code
sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves,voiremortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres par-
ties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page v, article 9.)
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ETEXPLOSION
Lesincendieset les explosionspeuvent résulter desscories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
bustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Necoupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
PAS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vosyeux et brûlervotrepeau. Le procédéà l’arcde plasma
produit une lumière infra-rouge et des rayons ultra-vio-
lets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ouun écran desoudeur. Porteztoujours des lunettes
de sécurité munies de parois latérales ou des lu-
nettes de protection ou une autre sorte de protec-
tion oculaire.

Date: November15, 2001 (Special) v GENERALINFORMATION
•Portezdesgantsdesoudeuretun vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suiventANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
*Ces valeurs s’appliquentoul’arcactuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
•Pour protégervotreouïe contre les bruitsforts,portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page v.
Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Docu-
ments, U.S. Government Printing Office, Washing-
ton, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’InstitutAméricain des NormesNationales (Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURESPROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (AWS), LE SOUDAGE ET LACOUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITSCOMBUSTIBLES, disponibleauprès de
laAmerican Welding Society,550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’AssociationAméricaine pour la Pro-
tectioncontrelesIncendies (NFPA), LESSYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire ProtectionAssociation, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL,disponible auprèsdela National FirePro-
tectionAssociation, BatterymarchPark,Quincy,MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202

GENERALINFORMATION vi Date: November 15, 2001(Special)
12. Norme CSAW117.2, CODE DE SÉCURITÉ POUR
LESOUDAGEET LACOUPE,disponible auprès de
l’Association des Normes Canadiennes, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3
13.ivret NWSA, BIBLIOGRAPHIESURLA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage,RECOMMANDATIONSDE PRATIQUES
SURESPOUR LAPRÉPARATIONÀLACOUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. NormeANSIZ88.2,PRATIQUESDEPROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

Date: November15, 2001 (Special) vii GENERALINFORMATION
Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the
National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Direc-
tive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Direc-
tive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manu-
facture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them
are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design
and manufacturing process. This is to ensure the product is safe, when used according to instructions in this
manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the
manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

GENERALINFORMATION viii Date: November15, 2001 (Special)
Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics®Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanshipor material. Should any failure to conform tothis warrantyappear withinthe time period applicable tothe Thermalproducts
as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and
notsubject to misuse,repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,at Thermal’s sole option,
of any components or parts of the product determined by Thermal to be defective.
THISWARRANTYISEXCLUSIVEANDISINLIEUOFANYWARRANTYOFMERCHANTABILITYORFITNESSFORAPARTICULAR
PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not
limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of
any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,
shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETYOR PERFORMANCE OFANYTHERMAL PRODUCT.
THISWARRANTY ISINVALID IF THEPRODUCTIS SOLDBYNON-AUTHORIZED PERSONS.
Thelimited warranty periodsfor Thermal productsshall be as follows (with the exception of XL Plus Series,CutMaster Series ,Cougar and
DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of
sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of
sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with
the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
MainPower Magnetics 3 Years 1 Year 2 Years 1 Year
OriginalMain PowerRectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
PowerSwitching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
SureLokTorches 1 Year 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001

Manual0-2577 1 INTRODUCTION & DESCRIPTION
SECTION 1: INTRODUCTION & DESCRIPTION
1.1 SYSTEM DESCRIPTION
The PAK MASTER
®
25™
European Air Plasma
Cutting System
Includes:
Figure 1-A PAK MASTER 25™ EMC Model Power Supply
• PAK MASTER 25™ EMC Model - The Power Supply provides
20 amps maximum output cutting current from a standard 110
volt, 50/60Hz AC single phase input service. All electrical,
pilot, and gas control circuitry is included.
• EMC PCH-25 Hand Torch with leads. Cut capacity is 1/4 inch
(6.4 mm) steel. Parts-In-Place (PIP) is an integral safety feature
of this torch to reduce the risk of electric shock.
• EMC PCH-25 Spare Parts Kit.
• 10 foot Work Cable with Clamp.
• 10 foot AC Input Power Cable.
AC POWERINPUT POWER
PRESSURE
TORCH
WORK
OPERATING
PRESSURE
50 PSI
(3.4 BAR)
CURRENT
RUN
SET
AC GAS DC
12 20
Made in the USA
R
40
20
100
100
80
60
2
1
345
6
bar
psi
A-01289
Note: Handle Not Shown
®

INTRODUCTION & DESCRIPTION 2 Manual0-2577
1.2 SYSTEM OPTIONS AND TORCH PARTS
System Options
Torch Parts Selection
These items can be used to customize a standard system for a
particular application or to further enhance performance.
• High Pressure Regulators - Available for air and Nitrogen (N2).
• Cutting Guide - This device provides precise cutting capability
with a hand torch. The guide fits 70° and 90° hand torches. The
kit includes roller guides and pivots that attach to the torch.
• The Leads Storage Kit (Catalog # 7-0253) - Provides a place to
store the EMC Pak Master 25 Torch Leads and is designed to
be mounted on the top of the Pak Master 25 EMC Model Power
Supply.
• Air Line Filter - Removes damaging contaminants and mois-
ture from the air stream when using compressed air.
Recommended Air Filter Assembly
Single Stage Inline Kit ................................... Cat. No. 7-0250
Replacement Cartridge*................................ Cat. No. 7-0251
The same torch parts are used for drag cutting and standoff
cutting. See Section 4.5, Replacing Consumable Torch Parts.
Order replacement parts by catalog number and description.
Address inquiries to your authorized Thermal Dynamics dis-
tributor.
Standard Shield Cup
Catalog No. 9-6003
Standard Cutting Tip
Catalog No. 9-4476
Electrode
Catalog No. 9-6006
Gas Distributor
Catalog No. 9-6007
A-00778

Manual0-2577 3 INSTALLATION
What's Included with
the Power Supply
Unpacking Procedure
Choosing a Location
CAUTION
CAUTION
NOTE
Included with each system is:
(1) Work Cable with Clamp (Attached)
(1) 14 AWG Single-Phase Input Power Cable (Attached)
(1) Operating Manual................................................Cat. No. 0-2577
(1) Spare Parts Kit - Includes:
(5) Standard Tips.................................................Cat. No. 9-4476
(3) Electrodes .......................................................Cat. No. 9-6006
(1) Gas Distributor ..............................................Cat. No. 9-6007
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify and
account for each item.
3. Inspect each item for possible shipping damage. If damage is
evident, contact your distributor and/or shipping company
before proceeding with system installation.
Select a clean, dry location with good ventilation and adequate
working space around all components.
The Power Supply is cooled by air flow through the front and
side panels. Air flow must not be obstructed. Provide at least 12
inches (300 mm) clearance on each side. Provide sufficient
clearance in front of the unit to allow access to front panel con-
trols (minimum 12 in or 300 mm).
Operation without proper air flow will inhibit proper cooling
and reduce duty cycle.
To prevent entry of cutting or other metal debris, the power
supply must not be operated in the vertical position. Operate the
power supply in the horizontal position or propped up by the
handle.
Review Important Safety Precautions (page 1) to be sure that the
selected location meets all safety requirements.
SECTION 2: INSTALLATION
2.1 UNPACKING AND CHOOSING A LOCATION

INSTALLATION 4 Manual0-2577
2.2 ELECTRICAL CONNECTIONS
WARNING
Power Requirements
NOTE
CAUTION
Disconnect primary power at the source before disassembling
the power suply, torch or torch leads.
The unit will operate from single phase 110V ±10%, 50/60 Hz.
The service should be fused for 15 amps.
Input power connections can be made directly to a properly
fused disconnect or by using a plug which conforms to the
recommended ratings.
The attached AC input power cable is three conductor, 14 AWG.
The primary power source, power cable, and plug all must
conform to local elecric code and recommended circuit
protection and wiring requirements.

Manual0-2577 5 INSTALLATION
Compressed Air or Nitrogen (N2), Only
50 psi (2.8 BAR)
125 scfh (59 lpm)
Maximum input gas pressure must not exceed 125 psi (8.6 BAR).
This cutting system must not be used with Oxygen (O2).
Air supply must be free of oil, moisture, and other contaminants.
Excessive oil and moisture may cause double-arcing, rapid tip
wear, or even complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear.
To test the quality of air, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moisture in the air will be
visible on the lens. Do not initiate an arc!
An air line filter, capable of filtering to at least 5 microns, is
required when using air from a compressor to insure that mois-
ture and debris from the supply hose does not enter the torch.
The front panel of the power supply is equipped with a female
1/4 NPT gas input fitting.
To use air or nitrogen from a high pressure gas cylinder:
1. Examine the cylinder valves to be sure they are clean and
free of oil, grease or any foreign material. Momentarily open
each cylinder valve to blow out any dust which may be
present.
2. Each cylinder must be equipped with an adjustable high-
pressure regulator capable of pressures up to 75 psi (5.3 BAR)
minimum and flows of up to 200 scfh (94 lpm).
3. Set the tank regulator to 75 psi (5.3 BAR). Use the regulator
on the front of the power supply to adjust the gas pressure to
the unit.
Refer to the manufacturer's specifications for installation and
maintenance procedures for high pressure gas regulators.
2.3 GAS CONNECTIONS
Gases
Pressure
Flow
CAUTION
WARNING
CAUTION
Checking Air Quality
Filtering
Gas Connections
Using High Pressure
Gas Cylinders
NOTE

INSTALLATION 6 Manual0-2577
Using Shop Air
CAUTION
CAUTION
Replacing Filter
Cartridge
NOTE
Do not use an air line filter with high pressure gas cylinders.
To use shop air from a compressor, refer to Figure 2-B and:
Air supply must be free of oil, moisture, and other contaminants.
Excessive oil and moisture may cause double-arcing, rapid tip
wear, or even complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear.
1. Install an air filter assembly (Cat. No. 7-0250) to the gas input
fitting on the front panel of the power supply. The air filter is
supplied with 1/4 NPT gas couplings. A quick disconnect
fitting is recommended on the filter body cap to allow easy
connection to the compressed air source.
2. Connect the air supply hose to the inlet fitting on the air filter
body cap.
When connecting a gas fitting to the filter cap, hold the cap flats
with a wrench. Over tightening the cap on the filter body can
damage the filter cartridge or cap gasket.
Air filter cartridge (Cat. No. 7-0252) should be replaced every 30
days, depending on the condition of the compressed air. If a
noticeable drop in air pressure occurs, the filter has become filled
with contaminants and must be replaced.
To replace cartridge, unscrew filter cap from body, slide out old
cartridge and insert new filter element. The filter cartridge fits
only one way. Filter cap must be hand tight only.
Supply hoses must be at least #4 hose (1/4 in or 6.4 mm mini-
mum inside diameter).
Figure 2-B Air Line Filter Gas Connections
Front Panel 1/4 NPT
Gas Fitting
Optional
Air Line Filter
Assembly
Supply Hose from Source
1/4 NPT Connection
Filter Cap
AIR FLOW
A-01271
Front Panel 1/4 NPT
Gas Fitting
Supply Hose from Gas
Cylinder Regulator
1/4 NPT Connection
AIR FLOW
A-01272
Using the System with Shop Air Using the System with Cylinder Air